Mask Assembly Auto-Teaching Position Correction
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Solution Overview
Problem
The reliability of mask assemblies in display device manufacturing varies due to inconsistencies in mask positioning and tension, affecting the deposition pattern's accuracy and consistency.
Innovation Solution
An apparatus and method for calculating auto-teaching data using position correction values, which involves a processing unit with a stage, mask, mask frame, and marking parts, where the photographing unit captures images to calculate first and second position coordinates, and position correction values are derived to improve mask assembly manufacturing reliability and reduce processing time.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional mask assembly manufacturing is used, then processing time is reduced, but reliability and positioning accuracy deteriorate
Solution Approach 1:
The system performs preliminary calibration by photographing marking parts at predetermined positions before actual mask manufacturing, calculates position correction values, and stores them for subsequent use. This preliminary action enables automated position correction during manufacturing without adding time to each individual production cycle.
Solution Approach 2:
The patent replaces manual positioning and measurement operations with an automated optical measurement system that uses cameras to photograph marking parts, automatically calculates position corrections, and applies them during mask assembly manufacturing. This substitution eliminates time-consuming manual interventions while improving reliability.
2Manufacturing precision
If manual positioning methods are used, then equipment complexity is reduced, but manufacturing precision deteriorates
Solution Approach 1:
Manual positioning operations are replaced with an automated optical measurement and calculation system that photographs marking parts, computes position correction values, and applies them automatically. This substitution significantly improves positioning precision despite the increased complexity of the automated system.
Solution Approach 2:
The system performs self-calibration by automatically photographing marking parts, calculating position corrections, and applying them without external intervention. The apparatus uses its own resources (camera, calculator, controller) to improve its manufacturing precision autonomously.
3Manufacturing precision
If position correction is not applied, then device complexity is reduced, but deposition pattern accuracy deteriorates
Solution Approach 1:
The patent introduces an automated position correction system that calculates correction values based on photographed marking parts and applies them during mask assembly manufacturing. This substitution improves deposition pattern accuracy by eliminating positioning errors while managing the complexity through automation.
Solution Approach 2:
The system establishes a feedback loop where marking parts are photographed, position errors are calculated, correction values are determined, and then applied to improve subsequent positioning accuracy. This feedback mechanism continuously improves deposition pattern accuracy without requiring complex manual adjustments.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The method enhances the reliability and efficiency of mask assembly manufacturing by correcting positioning errors and optimizing mask tension, leading to improved deposition pattern accuracy and reduced processing time.
Implementation Method 1
a photographing unit connected to the second gantry and that photographs the plurality of marking parts
Data Source
AI summary
Provided are an apparatus for manufacturing a mask assembly, a method for calculating auto-teaching data using the same, and a method of manufacturing a mask assembly using position correction values calculated by auto-teaching data calculation. The apparatus for manufacturing a mask assembly includes a processing unit including a stage, a mask, a mask frame, and marking parts, a first gantry disposed on the processing unit and movable in a first direction, a second gantry connected to the first gantry and movable in a second direction intersecting the first direction, a photographing unit connected to the second gantry and that photographs the marking parts, and a movement control unit that controls movements of the first gantry and the second gantry.